Solid oxide fuel cell stacks are complex structures that embody challenging materials problems not present in the idealized operation of a single cell. Chief among these are the complex interplay between the different layers within each individual cell, the overall curvature/geometry of the cell and the sealing/brazing points at the periphery of the cell/stack. We have recently begun to utilize a novel combination of tools - optical profilometry, laser dilatometry, and X-ray microdiffraction - to move the field toward a rational understanding of the observed component behavior. These must be addressed via robust modeling approaches before SOFC-based power generation becomes affordable. Each cell has a unique curvature that concentrates the applied assembly stresses. Major changes in geometry are generated by conflicts between the dimensional behavior of the relatively thick but porous anode layer(s) and the relatively thin but dense electrolyte. Cracking phenomenon during reduction and oxidation may or may not be related to overall curvature changes. The strength of the bond between the electrolyte layer and the first anode layer is of particular importance. In a stack-based geometry these dimensional changes provide additional sources of stress on any joints between these cells and the surrounding hardware. In addition, operational temperatures can ‘spike’ briefly during normal operation; such thermal transients are present throughout the system and must be factored into the design of the ‘ultimate’ seal. Along with key measurements of high temperature mechanical properties, this approach is expected to make fundamental contributions to both stack development and predictive modeling efforts.